Method of manufacturing automobile exhaust extensions



March 6, 1945. 1.. A. KOCH 2,370,737

METHOD OF MANUFACTURING AUTOMOBILE EXHAUST EXTENSION Filed July 1, 1942 Louis A. Koch -INVENTUR.

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ATTORNEY Patented Mar. 6, 1945 METHOD OF MANUFACTURING AUTOMO- BILE EXHAUST EXTENSIONS Louis A. Koch, Louisville, Ky.

Application July 1, 1942, Serial No. 449,332

4 Claims.

This invention relates to extensions or shrouds for motor vehicle exhaust pipes and methods of manufacturing the same, and more particularly to extensions of the type embodying a base member of relatively cheap material and a decorative overlay of more expensive material.

In the manufacture of prior types of extensions such as that disclosed in my Patent No. 2,232,395 issued February 18, 1941, considerable expense has been involved because of the steps followed in securing the overlay to the extension. A major object of my invention is to simplify the construction of such extensions and their method of manufacture to reduce the cost thereof and produce an improved product.

A further object of my invention is the provision of a novel method of making an'extension wherein the fastening means securing the overlay to the base member is utilized to predetermine the position of the extension on the exhaust pipe.

In the drawing:

Figure l is a plan of the blanks employed in forming the base member and the overlay.

Figure 2 is a side elevation of the blanks of Figure 1 after they have'been formed in substantially the shapes desired in the final extension.

Figure 3 is a perspective of a jewel or ornament that may be employed in the extension.

Figure 4 is a perspective of an insulating pad of material such as asbestos which is preferably employed to space and insulate the overlay and jewel against the temperature of the base member.

Figure 5 is a side elevation of the various elements making up the extension and illustrating them in partially assembled position.

Figure 6 is a side elevation of the extension in a later stage of manufacture.

Figure 7 is a section taken on the line 'l-'l of Figure 6.

Figure 8 is a perspective of a fastening tab employed on the blanks to fasten the overlay to 4 elevation of the tab of shapes they take in th final product, the front edges of the overlay and the base member secured together by the tabs provided thereon, and the overlay turned about the transverse axis of the fastening tab or tabs to its final position on the base member and secured thereto at some point spaced from the front edges of the two members. The latter securing means is preferably ,of a character such that it can be also utilized as a stop or abutment for the end of the exhaust pipe to predetermined the position of the extension thereon.

Referring to the drawing, H is a blank which is stamped to form the base member. Blank H include a section l2 forming the sleeve section of the base member and a section l3 forming the terminal or extending section. Ears 15 with holes 14 are provided on sleeve section l2 so that when the sleeve section is formed in a U-shape as shown in Figure 7, bolts may be passed through opposing openings IE to clamp the extension to the exhaust pipe. Terminal section I3 is stamped with extending lugs l6 which are preferably reduced in section adjacent their point of connection to the terminal section at I! to facilitate their being bent for a purpose later described. Terminal section [3 terminates in a front edge 18.

Overlay blank l9 includes a front edge 2| having tabs or lugs 22 thereon, an aperture 24, a curved rear edge 25 and extending lugs 26 closely adjacent thereto. Lugs 22 and 26 may be similar in shape to lugs l6 if desired.

After blanks I l and I9 are stamped in the shape illustrated, they are formed in the shape shown in Figure 2, sleeve section l2 being formed in generally U-shape and terminal portion l3 and overlay I9 being bent to correspond with one another in a general fan shape so that the overlay will cover the terminal section.

Prior to the assembly of the formed overlay and base member, the base member may be either enameled, painted, plated or otherwise decorated as desired as can the overlay. Preferably the base member which is formed of relatively cheap material is enameled. As the overlay is preferably formed of a non-corrosive material and highly polished material such as stainless steel, it is preferably left a is.

In the first assembly step shown in Figure 5, tabs 22 on overlay l9 are placed in contact with the upper surface of edge I8 of terminal portion 13 and spot-welded or equivalently fastened thereto. To insure the necessary contact with base member I l which may have been enameled.

in opening-24 .andasbestos pad-3| placed'there beneath. As jewel 21 includes a section 28 of smaller size than aperture 24 and a section 29 of large size, overlay 19 will engage section 29 to hold the jewel securely imposition atop-parks 3|. verse axes of tabs 22 to the position shown in Overlay I9 is then turned aboutwthe trans-.

Figure 6. In this position, asbestos pad3|--will-- be in engagement with the upperlsurfacewofi-the 5 base member and the lower surface of the jewel and overlay. It thus operates to space the =overlay from.the base member, provides a thermal insulator, therebetween, and maintains the jewel in position.,As .will .be notedin Figure 6, when the'overlay is turned toits .final position,.tabs;26 a

ofthe overlay and tabs. l6 of thebasememben come into registrations Thesetabs are preferablyispot-welded or similarly, fastened together. and bent inwardly as shown in. Figure 7 whereby they operateaslstopsor. abutments for the end of the exhaust pipe when .the extension is mountedthereon, thus .predetermining the positionof the extension.

It will be..understood thatin the event either the basemember or the overlay member is coated with insulating material orpainted, tabs l6 and 26jwill beformedas shown in Figures 8 and 9 to Y insure the necessary contact forspot-welding,

Figure 10, illustrates anoverlay blank and a base member blank-of the same general shape as.

shown. in Figure 1 except that the end tabsare omitted-from the overlay blanklflfs In lieu ofv tabs 22,.tabs or lugs 33 .are stampedintegrally with. base memberblank I I.

joined .-in a manner similartothat shown in,Fig-.

ure..5 except that tabs,33.are placed in contact andsecured to the surface.v of the. overlaynblankthat becomes the lower surface in the final as-- sembled-extension.

In forming overlay blanks l9 and. I9, section 25.is curved generally as .shown in Figuresfi and 7 so that the rear end .of the overlaywhich is spaced from the base member forms an air. scoop q 34 ,whichoperatesto collectair and conduct. it

In the assembly of theseblanks, after they are formed, they are intojthe .space between the overlay and the: base":

member to efiect cooling thereof andfurther-prevent any damage. or .cliscolorationv ofqthe; overlay, w byreason of the hightemperature of the exhaust gases.

Having described-my -invention, I claim:;.

1. In. a process ,ofmanufacturing. an extension:

for a motor vehicle exhaust pipe, said extension being of the type including a base member and an overlay member of a size to cover a portion of the base member, comprising the steps of; blanking the base member and the overlay member, the

front end of one of said members being formed with at least one projecting tab; shaping the blanks to substantially the forms required in the final extension; placing the base member and the overlay member in inverted relation relative to one another with the tab on the front edge of the one member in contact with the front edge of 1 the =.other.- member; permanently connecting the front ends of both members together by securing the tab to the other member; folding the tababout a transverse fold line while turning the overlay memberabout such fold line to its final permanent position on the'base member; and securing the overlay member to the base memberxatha point spaced from the front edges of saidmembersjto retain theoverlay in its final permanent position on the base member.

2. The process of claim,1 wherein the base member and, the overlay member are blanked withside tabs on their side edges adapted to register when the overlay is turned to its final position,,.and the side tabs are-secured-together.

3. The process of claim 1 wherein. the base 7 member and the overlay areblanked with side tabs ontheir side edges adapted to register when the overlay is turned to its final position, and theflside tabs ,are. secured together and bent inwardlyito forme stop arranged to abut the end of a motor vehicle exhaustpipe when installed thereonto predetermine the position of the extension.

4. In'ja process of manufacturing an extension for'a motor vehicle exhaust pipe, said extension being- .of .the type including a base member and an overlay member of a size to cover a portion of .thebasemember, comprising the steps of;

blanking ,the base member andthe overlay memher, the frontendof the latter being formed with at least one projecting tab; shaping the blanks to another :with the tab-zin. contact withione edge of the. base member; permanently connecting the front-ends of 'both' members-together by securing the .tab to the base 1 member; bending the tababouta transverse line while rotating the overlay member about such transverse line to its final permanent position on the base member;

and securing a portion of the overlay. spaced from the .tab t.0 the .base member. to retainthe overlay in its final permanent position on thebase member:

LOUIS A. KOCH. 1 

